Foldable and flexible laminated mat

ABSTRACT

A chair pad or a roll up mat that can be manufactured from medium density fiberboard with a laminate surface decorative layer applied thereon. The laminate is treated with various protective coatings, to add resistance to natural deleterious factors including water and dirt. The chair mat includes a series of planks, held together by tape, with an under layer of a mesh, all applied by resin together, and having a bottom layer of a felt or rubber to provide cushioning when the mat is applied upon a floor or surface, and to function as a living hinge, when it is rolled up or folded for storage or shipment.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation-in-part of the patent application and claimspriority to the provisional patent application having Ser. No.12/214,007, filed on Jun. 16, 2008, which claims priority and is acontinuation of the patent application having Ser. No. 10/905,827, filedon Jan. 21, 2005; this application also claims priority as acontinuation-in-part of the application having the Ser. No. 12/460,841,filed on Jul. 23, 2009, which is a continuation-in-part of patentapplication having Ser. No. 11/468,290, filed on Aug. 29, 2006, whichclaims priority to the provisional patent application having Ser. No.60/741,990, filed on Dec. 2, 2005.

FIELD OF THE INVENTION

This development relates to a laminated roll up or foldable mat that maybe manufactured from medium density fiberboard, and having a surfacelayer of a laminated decorative paper, or a wood veneer, with aprotective coating applied thereon, to furnish a strengthened mat ofslats that can be subjected to roll up, or folding, as when not inusage.

BACKGROUND OF THE INVENTION

This invention primarily relates generally to chair mats, and moreparticularly, to medium density fiberboard laminated chair mats.

Chair mats have long been used as a protective covering for a floor areaon which a chair rest or some other furniture item locates. The chairmat is utilized to protect the underlying floor, or even a rug, fromdamage due to wear and tear caused by the chair and its constantmovement, and/or from the occupant of the chair moving about within thefloor area on which the furniture rest. A typical chair mat is made ofplastic, or other appropriate material, that is semi flexible, butresilient enough such that when the chair mat is placed on the floorarea a semi ridged surface is provided by the chair mat. The semi ridgedsurface makes it easier to move about in the floor area, while occupyinga chair with wheels.

Most chair mats are of a unitary one piece flattened body. Some chairmats as indicated are made of plastic. However, others are made of ahardwood material to provide a better aesthetic appeal. Hardwood chairmats, however, are not flexible, are very expensive, and do tend tocrush down on any underlying rugs, due to their weight. Such chair mats,particularly the larger ones, are difficult to move about and verydifficult to ship because of the special packaging required. Obviously,cost can be an excessive factor. Also, one alternative to a hardwood padwould be the subject matter of this invention, to utilize a mediumdensity fiberboard (MDF) laminate, which can also be used for a chairmat if processed like hardwood.

Thus, the concept of the current invention is to provide a much lesserexpensive woodlike material, of reduced weight, and more easier to workwith, type of plank or slats of such MDF that can be applied inadjacency, and then affixed together in the manner as described in thisinvention, and in co-pending prior applications, into a roll up orfoldable type of chair mat, yet one having the aesthetic appeal of atreated or stained hardwood pad as known in the prior art.

SUMMARY OF THE INVENTION

This invention contemplates the formation of a MDF/laminate chair matformed from multiple elongated MDF/laminate planks that have beenprocessed like hardwood flooring. The chair mat provides a substantiallyhardwood ridged surface, but the mat can be rolled up like a chair matfor ease of transport, storage, or shipment. The fiberboard planks havesufficient thickness such that when they are bonded to a backing in anadjacent side by side manner, a substantially ridged surface isprovided. The planks are not adjacent connected along their side edges,and therefore, the mat can be rolled for ease of transport and storage.

Medium density fiberboard is an engineered wood product formed bybreaking down hardwood or softwood residuals into wood fibers, often ina defibrator, and combining it with a wax and a resin binder, formingpanels by applying high temperature and pressure to compress them into awoodlike product of significant density. MDF is denser than plywood. Itis made up of separate fibers, not wood veneers, but can be used as abuilding material similar in application to plywood. It is stronger andmuch denser than normal particle board. The name derives from thedistinction and densities of fiberboard. Large scale production ofmedium density fiberboard began many decades ago, and such fiberboardhas now been perfected where it can be used in the manufacture offurniture, such as the chair pad or mat of this invention.

There are various types of MDF/laminate flooring including tongue andgroove type, and the type that needs to be butted together. Thelacquered flooring panels are finished using wear resistant UV lacquerand the unlacquered flooring panels need to be coated/waxed and polishedafter installation. The strength of MDF/laminate boards can be betterthan common wood boards due to the high pressure and high temperature oftheir manufacturing process.

Furthermore, wood is subject to deterioration, splintering, and crackingwhen subjected to too much drying, which the fiberboard of thisinvention avoids.

It has been found that the MDF/laminate material used in this inventionis very durable for a chair mat application, however, the constructionof many MDF/laminate mats are ridged, lacking the capability to flex orbend. A novel MDF/laminate chair mat construction is needed in theindustry, and it is believed that this current invention may satisfythat requirement.

In the formation of the mat of this invention, the formed planks have apaper laminate applied over their surface, and such paper may haveaesthetics related to that as providing a wood appearance, or it mayhave almost any appearance that may be desired for the chair mat whenemployed. Or, there is the potential that veneer may be applied upon thesurface of the planks, to give a natural wood appearance.

The planks of this invention are then coated with UV coatings, which areapplied onto the surface of the MDF/laminate planks. One embodiment ofthe invention can have up to seven coats of UV protection. TheMDF/laminate can be arranged with a series of planks lying next to oneanother, and then assembled into the chair mat. The chair mat can thenbe rolled or pressed thereby compressing all of the layers of the chairmat simultaneously.

During the assembly process, a mesh sheet is placed on the bottom sideof the chair mat. The mesh sheet can be made of nylon fibers, or otherpolymers. A mastic layer is then placed over the nylon mesh sheet,thereby adhering it to the undersurface of the aligned planks, and thena final layer of high density felt or sisal can be applied under themesh sheet. Such a high density layer can be preferably of aboutapproximately 2 mm in thickness. The chair mats can then be cut to thedesired dimensions. This bottom high density layer can be made of thematted felt, rubber, or polymer padding, bonding over and to the resinmaterial layer, and this layer can function as a type of living hinge,for the aligned slats, when they are rolled up, or folded into closureswhen used as a chair pad, thereby eliminating the need for usage of anymetal hardware, for hinge purposes, in the construction, manufacture,and usage of this current invention.

It is, therefore, the principal object of this invention to use mediumdensity fiberboard planks in the construction of a chair pad or mat, andwhich may be laminated with a surface coating of paper, or veneer, toadd to its attractiveness.

A further object of this invention is to provide for the use of lowercost materials in the fabrication of a high strength chair mat or pad,when employed for those purposes.

Another object of this invention is to provide a mat or pad that can berolled up or folded, as during nonusage, or during shipment, during itsusage.

Another object of this invention is to provide a laminated structure fora pad or mat, one fabricated of fiberboard, but which in its finalprocessing, after all of its laminated layers have been broughttogether, and may be subjected to pressure compressing to assure itsintegrity even after prolonged usage.

These and other objects may become more apparent to those skilled in theart upon review of the summary of the invention as provided herein, andupon undertaking a study of the description of its preferred embodiment,in view of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference may bemade to the accompanying drawings, in which:

FIG. 1 is a perspective view of the foldable and flexible laminated mator pad of this invention; and

FIG. 2 is a perspective partial cutaway view of the pad or mat of thisinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

According to the present invention, various views of the foldable andflexible laminated mat or pad of this invention are shown in FIGS. 1 and2. In the embodiment of the present invention, comprising medium densityfiberboard laminated planks, these are laid in adjacency and a felt orsisal backing provides both the adherence of the planks in adjacency,and furnishes a backing for resting upon the floor, in addition tofunctioning as a living hinge when the mat or pad is to be rolled up, orfolded, for storage or shipment. The details of the invention can bebetter understood by referring to FIG. 1. This is a perspective of thepresent pad or mat 100, and the pad is constructed including a pluralityof elongated medium density fiberboard planks 102, arranged lengthwisein a side by side manner where the long side edge of each plank can beabutted against the adjacent long side edge of the adjacent planks. Theabutting relationship between the planks can form a mat, as at 114. Theadjacent long side edges of the planks can be unattached. The laminatedchair pad as shown is cut into a typical chair pad pattern outline thatis substantially rectangular in design, with adjacent corner sectionscutaway. See the notched cutaway areas 104 and 108.

The certain MDF/laminate that can be used in the manufacture of thepresent chair mat is oxidize and gives it an extra step in making theMDF/Laminate more impermeable to water and dirt. Once the elongatedplanks have been processed, they can be laminated, with a paperovercoating, which may be to any design as desired. For example, it mayhave a wood grain finish, or some other appearance, depending upon thedesires of any purchaser. Furthermore, once the planks have beenprocessed, they are adjacently aligned lengthwise, and in a side-by-siderelationship. A fibrous strip, or multiple threads and/or a fibrous tapematerial, as at 210, can be applied to the underside to connect theMDF/laminate planks. A fiber mesh sheet 206 can then be applied andbonded to the underside to hold these strips together. A resin materiallayer is then applied to the fiber mesh sheet 206, bonding the meshsheet to the underside of the MDF/laminate layer portion of the planks,in addition to the tape material, to form a means for holding theadjacent planks together, in their assembly.

Applied to the bottom of the pad is a layer 212, which is adhered by theresin material layer to the undersurface of the mesh sheet, and thestrips 210, and this particular layer for the mat is formed of a highdensity layer made of matted felt rubber, or polymer matting bonded bythe resin layer and thereby functions not only as a cushion for the matwhen applied upon the floor, but further functions as a living hinge forthe slats when the mat is rolled up, or if formed as a chair pad, whenthe sections of the pad are folded over into closure. After applicationof the layer 212, the entire mat can then be pressed thereby compressingall of the layers of the chair mat into almost an integrated structure,may even have some heat applied, in order to provide for the bonding bythe resin material into an integrated structure. The pressure rollingachieves a bonding of all of the components together, into the desiredformation of the floor mat or chair pad of this invention.

From the aforementioned description, a foldable chair mat has beendescribed. The foldable chair pad, or roll up mat, is uniquely capableof folding wooden panels into a light compact form for shipping andeventual placement at its final location. The foldable chair pad may bemanufactured from many materials, including but not limited to wood,laminated wood, fiberboard, and other wood composites.

In addition, the resin layer of the formed mat may be of a mastic resinlayer.

Furthermore, the laminated planks of the medium density fiberboard maybe of higher or lower densities of fiberboard, depending upon theirintended usage. The planks are made of a laminated surface, and haveapplied thereto by gluing decorative paper to the top of the plank forenhanced appearance. The planks will also have several layers ofurethane coating applied thereon. As many as seven layers of coatinghave been applied, to attain the quality appearance for the mats, asmarketed.

The fibrous tape strip that is used to hold the planks initially inadjacency may be made of a polymeric fiber. The fiber mesh sheet that isused to bond the entire planks, and tape, together, in addition toholding the felt, rubber or polymer high density under layer may be anylon fiber mesh sheet.

Obviously, the final peripheral shape of the chair pad may besubstantially rectangular, and wherein adjacent corners may be notchedaway, for convenience of location, particularly when partially arrangedunder a desk.

Variations or modifications to the subject matter of this invention mayoccur to those skilled in the art upon review of the mat or pad asdescribed herein. Such variations, if within the spirit of thisinvention, are intended to be encompassed within the scope of any claimsto patent protection issuing hereon. The review of the preferredembodiment of the invention, and its depiction in the drawings, are

-   -   set forth for illustrative purposes only.

1. A mat or pad for use for supporting a chair, other item of furniture,or other equipment, and comprised of a plurality of elongated flatlaminated planks arranged lengthwise in adjacency, with each plank beingarranged contiguously in a substantially abutting relationship withrespect to the adjacent planks, each said plank comprising a length offiberboard composite, each plank having a covering thereon, laminatedonto the fiberboard to add to the aesthetics and appearance of eachplank, said plurality of adjacently arranged planks having a series offiberous tape strips connected orthogonally to the underside of saidplanks for forming a formed mat or pad, a fibrous mesh sheet applied onthe underside of said laminated planks and said tape strips, a resinmaterial layer applied to the fiber mesh sheet underside for bonding themesh sheet to the underside of the laminated planks and the fibrous tapestrips of the formed mat, and a high density layer made of one of mattedfelt, rubber and polymer matting bonded onto the resin layer material,for adhering the layer to the underside of the formed mat, and whereinsaid planks, tape, mesh sheet, and high density layer being subjected topressure and rolled to enhanced the bonding of the laminated plankstogether.
 2. The mat of claim 1 wherein the fiberboard comprises mediumdensity fiberboard.
 3. The mat of claim 1 wherein the resin layer is amastic resin layer.
 4. The mat of claim 3 wherein the laminated planksare formed of medium density fiberboard, and the laminated covering isapplied by glue, said covering comprising decorative paper as applied tothe top of the fiberboard planks during fabrication.
 5. The mat of claim4 wherein a plurality of layers of urethane coating are applied to thelaminated paper covering of the planks.
 6. The mat of claim 5 whereinthe high density layer is made of sisal.
 7. The mat of claim 6 whereinthe fibrous tape strip is a polymeric fiber tape strip.
 8. The mat ofclaim 7 wherein the fiber mesh sheet is a nylon mesh sheet.
 9. The matof claim 8 wherein the peripheral shape of the mat is substantiallyrectangular and having its front corners cutaway to provide for itsaccommodation during usage.